CAREER: Toward RIPEST Photopolymer Additive Manufacturing (PAM): A Cyber-Physical System of Novel Dual-wavelength Photoinhibition aided PAM

职业生涯：迈向最成熟的光聚合物增材制造 (PAM)：新型双波长光抑制辅助 PAM 的网络物理系统

基本信息

批准号：
2238557
负责人：
Xiayun Zhao
金额：
$ 65.76万
依托单位：
University of Pittsburgh
依托单位国家：
美国
项目类别：
Standard Grant
财政年份：
2023
资助国家：
美国
起止时间：
2023-05-01 至 2028-04-30
项目状态：
未结题

来源：
https://www.nsf.gov/awardsearch/showAward?AWD_ID=2238557&HistoricalAwards=false
关键词：
CAREER Toward RIPEST Photopolymer Additive

项目摘要

Photopolymer additive manufacturing (PAM) uses light to cure photosensitive materials and is one of the most versatile technologies to fabricate components with higher resolution compared to existing polymer manufacturing technologies. However, the state-of-the-art photopolymer additive manufacturing technologies still suffer an intractable issue of overcuring, which is detrimental to the structural integrity of printed parts. This Faculty Early Career Development (CAREER) grant supports research to elucidate the fundamental science of light propagation and photochemistry reactions for establishing a smart dual-wavelength photoinhibition aided PAM process. This new process allows to manipulate cure and curb exposures of the PAM processing so that the geometrical fidelity and functional integrity can be enhanced. If successful, this project will impact numerous applications including biochips, electrodes, soft robots, metamaterials, and others that demand precision manufacturing of parts with complex shapes and strengthened performance. This project will provide educational activities aimed to train future leaders to pursue manufacturing-related careers and improve the diversity of the STEM workforce by reaching out to historically underrepresented communities.The overarching goal of this CAREER project is to realize Rapid, Intelligent, Precise, Extensive, Sustainable, and Transformative (RIPEST) PAM. The primary research objective is to establish a novel digital light processing method - DLP2Curb that capitalizes on photoinhibition induced by a second wavelength light to curb curing parts, via a holistic cyber-physical approach that combines physics-guided surrogate modeling with real-time sensing and control. Thrust 1 elaborates the DLP2Curb process dynamics and materials behavior through multiple physical regimes, temporal stages, and spatial scales to unravel the causes of overcuring and the curb reaction paths by constructing a digital twin. Thrust 2 aims to achieve non-contact, full-field operando characterization of PAM in real time. In-process part properties will be measured by deploying in-situ interferometric and ultrasonic monitoring systems along with physical sensor models and data analytics methods. Thrust 3 develops a real-time control method via deep reinforcement learning of model predictions and in-situ measurements feedback. With case studies such as micropillars and lattices, this project will demonstrate the potential ability of DLP2Curb to unlock efficient precision manufacturing of sophisticated parts with exact geometry and exquisite details.This award reflects NSF's statutory mission and has been deemed worthy of support through evaluation using the Foundation's intellectual merit and broader impacts review criteria.

光聚合物增材制造 (PAM) 使用光来固化光敏材料，与现有的聚合物制造技术相比，它是制造分辨率更高的组件的最通用的技术之一。然而，最先进的光聚合物增材制造技术仍然面临着过度固化这一棘手问题，这不利于打印部件的结构完整性。该教师早期职业发展 (CAREER) 资助支持研究阐明光传播和光化学反应的基础科学，以建立智能双波长光抑制辅助 PAM 过程。这种新工艺可以控制 PAM 处理的固化和控制曝光，从而增强几何保真度和功能完整性。如果成功，该项目将影响众多应用，包括生物芯片、电极、软机器人、超材料以及其他需要精密制造复杂形状和增强性能零件的应用。该项目将提供教育活动，旨在培训未来的领导者从事与制造相关的职业，并通过接触历史上代表性不足的社区来提高 STEM 劳动力的多样性。该职业项目的总体目标是实现快速、智能、精确、广泛、可持续和变革性（RIPEST）PAM。主要研究目标是建立一种新颖的数字光处理方法 - DLP2Curb，该方法利用第二波长光诱导的光抑制来抑制固化部件，通过将物理引导的替代建模与实时传感相结合的整体网络物理方法，控制。 Thrust 1 通过多个物理状态、时间阶段和空间尺度详细阐述了 DLP2Curb 过程动力学和材料行为，通过构建数字孪生来揭示过度固化的原因和遏制反应路径。 Thrust 2 旨在实时实现 PAM 的非接触式全场操作表征。将通过部署原位干涉测量和超声波监测系统以及物理传感器模型和数据分析方法来测量过程中零件的属性。 Thrust 3 通过模型预测和现场测量反馈的深度强化学习开发了一种实时控制方法。通过微柱和晶格等案例研究，该项目将展示 DLP2Curb 的潜在能力，以实现具有精确几何形状和精致细节的复杂零件的高效精密制造。该奖项反映了 NSF 的法定使命，并通过使用基金会的智力价值和更广泛的影响审查标准。